Method for constructing composite building boards using dissolvable films

ABSTRACT

Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the un-dissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a continuation of applicationSer. No. 12/794,959 filed on Jun. 7, 2010, and entitled “Method forConstructing Composite Building Boards using Dissolvable Films.” Thecontents of this co-pending application are fully incorporated hereinfor all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method for constructing composite buildingboards. More particularly, the present invention relates to the use ofdissolvable films in the construction of composite gypsum buildingboards.

2. Description of the Background Art

Building board, also known as wallboard, plasterboard, or drywall, isone of the most commonly used building components in the world today.Building board is frequently used within the interior of a dwelling,where it functions both as a finished wall covering and as a structuralroom partition. Building board can also be used on the exterior of adwelling, where it serves as a sheathing to provide weather protectionand insulation. Building board can also be used as an interior facingfor other structures as well, such as stairwells, elevator shafts, andinterior ducting.

One particularly popular form of building board is known as glassreinforced gypsum (GRG) board. An example of one such board is disclosedin U.S. Pat. No. 4,265,979 to Baehr et. al. Baehr discloses a buildingboard constructed from opposing glass fiber mats with an intermediategypsum core. This construction provides a hardened external surface andis an improvement over earlier paper faced boards.

Current GRG manufacturing techniques have some significant drawbacks.Namely, during construction, some of the individual mat fibers are notcovered by the gypsum slurry core and are therefore exposed. Thesefibers have a tendency to dry out and disengage from the board. As aresult, free floating glass fibers tend to accumulate on and damageassociated forming equipment, such as forming tables, forming plates,motor drives, bearings, and the like. The presence of disengaged fibersalso presents a significant hazard to workers who must wear appropriatesafety masks so as not to ingest the fibers. The most common way tocombat this problem is through the use of expensive dust collectionequipment and/or the periodic and repeated cleaning of the formingequipment.

A subsequent board manufacturing technique is described in commonlyowned U.S. Pat. No. 4,378,405 to Pilgrim. The contents of the Pilgrimpatent are fully incorporated herein by reference. Pilgrim discloses aGRG board that is faced on one or both sides with a porous, nonwovenglass mat. The glass mat of Pilgrim is slightly embedded into the slurrycore. This is accomplished by vibrating the gypsum slurry to cause it topass through the porous openings in the mat. Embedding the mat withinthe core as taught in Pilgrim results in a thin film of slurry beingformed on the outer surface of the board. Building boards with thisconstruction are referred to as embedded glass reinforced gypsum (EGRG)boards.

EGRG boards eliminate, or greatly reduce, the presence of exposed fibersand greatly reduce the presence of free floating fibers. However, theconstruction of EGRG boards also has its drawbacks. Namely, EGRG boardsrequire the application of large amounts of gypsum slurry. This slurryleaks from the boards during manufacture and accumulates on associatedforming equipment. Thus, during manufacture, the forming tables, formingbelts, and associated rollers and motors are exposed to substantialbuild-ups of gypsum slurry. Over time, if not repeatedly cleaned, themanufacturing process comes to a complete stop. Thus, in traditional GRGand EGRG building board manufacturing techniques there is a substantialcapital investment in equipment designed to clean the forming areas.

Additionally, even in the construction of EGRG boards, there is acontinuing problem with some fibers becoming exposed, dried anddetached. This, in turn, results in the accumulation of free fibers onthe forming tables, forming belts and associated rollers and motors. Aswith the excess gypsum slurry, these fibers must be removed in order toprevent downtime.

During the drying of GRG boards, excess water in the gypsum core isboiled off and passes through the facing mats. These vapors serve tobreakdown and weaken binders within the mats and surrounding core. This,in turn, releases silica-based granules that are likewise damaging toforming tables, forming belts, and associated rollers and motors. This,too, leads to the need for periodic cleaning and maintenance.

Thus, there exists a need in the art for improved building boardmanufacturing techniques. More specifically, there is a need in the artfor manufacturing techniques that minimize the acumination of gypsumslurry and/or free floating fibers on associated forming equipment.There also exists a need to minimize capital investment needed toconstruct GRG and EGRG building boards. There is yet another need toeconomically produce GRG and EGRG building boards with improved physicalcharacteristics. The present invention is aimed at achieving theseobjectives.

SUMMARY OF THE INVENTION

It is therefore one of the objectives of this invention to manufacturebuilding boards in a way that minimizes the accumulation of slurry onassociated forming equipment.

It is also an object of this invention to construct fiber reinforcedbuilding boards via techniques that minimize and/or eliminate thepresence of exposed and/or free floating fibers.

It is still yet another object of this invention to utilize adissolvable film during the manufacture of building boards.

Another object of this invention is to use a dissolvable film in theconstruction of building boards, where in the un-dissolved state, thefilm acts as a containment envelope for slurry and glass fibers.

Still yet another object of this invention is to use a dissolvable filmin the construction of building boards, where the dissolved filmimproves the physical properties of the resulting building board.

The foregoing has outlined rather broadly the more pertinent andimportant features of the present invention in order that the detaileddescription of the invention that follows may be better understood sothat the present contribution to the art can be more fully appreciated.Additional features of the invention will be described hereinafter whichform the subject of the claims of the invention. It should beappreciated by those skilled in the art that the conception and thespecific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be had to the following detailed description taken inconnection with the accompanying drawings in which:

FIG. 1 is an elevational view of the first part of the manufacturingprocess wherein the slurry is applied to fiber mats;

FIG. 2 is an elevational view of the second part of the manufacturingprocess wherein the building boards are cut and flipped;

FIG. 3 is an elevational view of the third part of the manufacturingprocess wherein the building boards are delivered into a series ofdryers;

FIG. 4 is a cross section of the fourth part of the manufacturingprocess wherein the building boards exit with a previously applied filmdissolved;

FIG. 5A is a detailed cross section of the building board taken fromFIGS. 1 and 2.

FIG. 5B is a detailed cross section of the building board taken fromFIG. 2.

FIG. 5C is a detailed cross section of the building board taken fromFIG. 4.

Similar reference characters refer to similar parts throughout theseveral views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present disclosure relates to building board manufacturingtechniques that minimize the build-up of slurry on associated formingequipment and that also produce panels with enhanced physicalproperties. The method involves applying a dissolvable film to one ormore fiber mats at the outset of the forming process. In theun-dissolved state, the film acts as a containment envelope for theslurry and any free floating glass fibers. During subsequent curing, thefilm dissolves when heated and by the passage of vaporized water throughthe film. In its fully dissolved state, the film coats any exposedfibers and sinks down into the slurry core. This eliminates exposedfibers and produces building boards with enhanced physical properties.The disclosed method can be utilized in the production of GRG or EGRGboards.

The present method is carried out via a building board production line10. The various sections of this line are sequentially illustrated inFIGS. 1-4. The various components of the building boards are assembledin the first stage illustrated in FIG. 1. As is known in the art,conventional GRG/EGRG building boards are formed from one or more glassfiber mats that are lined with a gypsum slurry. In the depictedembodiment, first and second glass fiber mats (22 and 24, respectively)are adhered to opposing sides of a slurry core 26. Slurry core 26 ispreferably formed from a gypsum slurry. Mats 22 and 24 are dispensedfrom upper and lower rolls (28(a) and 28(b), respectively).

The mats are preferably constructed from a series of nonwoven, randomlyaligned glass fibers. The mats are also preferably pre-coated with anorganic or inorganic resin binder to hold the individual fiberstogether. However, the disclosed method can be carried out with avariety of other mat constructions. For instance, the mats can be formedfrom woven or nonwoven filaments of organic and/or inorganic fibers.Continuous or non-continuous filament fibers can likewise be used.Additionally, the mats can be supplied uncoated, with the resin binderbeing applied at a point along the production line 10.

As illustrated in FIG. 1, the lower glass mat 22 is supplied to aforming table via lower mat roll 28(b). FIG. 1 also illustrates a film32 being adhered to the underside of lower glass mat 22 prior toapplication of gypsum slurry 26. Glass mat 22 is referred to as beingthe “lower” glass mat in that it is initially beneath the upper mat 24during the assembly process. However, it is understood that duringsubsequent processing mat 22 is cut into individual boards, which arethen inverted or flipped. As such, lower glass mat 22 eventually becomesan upper glass mat 22; namely, after being flipped, mat 22 is orientedover mat 24. Additionally, although underlying film 32 initially facesthe forming table, it is eventually exposed after the board is flipped.

A variety of materials can be used for film 32. In the preferredembodiment, film 32 is a water soluble, synthetic polymer, such as aPolyvinyl Alcohol (“PVOH”). PVOH films are preferred because they aretemperature sensitive, reactive to water, and gas permeable during phasechange, and heat curable. In the preferred embodiment, PVOH film 32 isbetween approximately 0.5 and 2.5 mils thick. By way of non-limitingexample, a PVOH film 32 having a thickness of approximately 1.8 mil ispreferred. One suitable PVOH film is made by Monosol® of Portage, Ind.Other water and/or heat dissolvable films can be utilized by the presentmethod. For example, certain water dissolvable polyethylene-basedcomposite films produced by Aicello Chemical Co., Ltd. of Toyohashi,Japan have been found to be acceptable. Alternatively, heat dissolvablefilms may also be used such as certain Ethylene Vinyl Alcohol (“EVA”)films. Still yet other films that dissolve in the presence of heatand/or water may suffice.

The film 32 is stored in a roll 34 and is applied via a slip sheet.Proper adherence is achieved by delivering mat 22 and film 32 throughopposing hot laminating rollers 33. It is preferred that the width offilm 32 be equal or slightly greater than to the width of glass mat 22to ensure that the entire undersurface of glass mat 22 is covered byfilm 32. After being passed through the hot laminating rollers 33, film32 preferably has a tackiness that assists in adhering film 32 to mat22. Alternatively, film 32 is formed from a material that does notinterfere with proper adherence between film 32 and mat 22. Thetackiness of film 32 also assists in adhering the upper mat 24 to thefolded edges of lower mat 22 during subsequent processing as describedbelow. As noted hereinafter, upper mat 24 may or may not include a filmlayer 32.

Film 32 can also be adhered to mat 22 by way of a heat activatedadhesive. This adhesive can be applied to mat 22 prior to unrolling themat 22 in the gypsum board manufacturing process. This would allow film32 to be laminated to mat 22 via a simple low cost heated roller orcompression nip. Suitable adhesives include a hot melt polyolefinadhesives. Ethylene vinyl acetate (EVA) adhesives can likewise be used.Organic and/or inorganic cold thermal setting or hot appliedthermoplastic adhesives can likewise be utilized.

Alternatively, film 32 can be coated with a suitable heat activatedadhesive along production line 10 prior to film 32 being secured to mat22. The preferred adhesive in this instances would be a tacky adhesivewith a long open time. In still yet another embodiment, film 32 could belaminated to glass mat 22 prior to in-plant use. Namely, mat 22 would bereceived by the plants with film 32 already laminated to it.

Once film 32 is laminated to mat 22 one or more layers of gypsum slurry26 are then applied to the upper surface of lower mat 22. In thedepicted embodiment, a mixer 36 supplies a series of gypsum slurrylayers to mat 22. In the depicted embodiment, slurry 26 is supplied frommixer 36 via outlets 38(a), 38(b), and 38(c). The first slurry layer issupplied via outlet 38(a). The slurry can be applied at varyingdensities, and/or with varying additives, from the different outlets38(a), 38(b), and 38(c). A similar slurry application technique isdescribed in commonly owned U.S. Pat. No. 6,878,321 to Hauber et. al.and entitled “Method of Manufacture of Glass Reinforced Gypsum Board andApparatus Therefor.” The contents of this commonly owned patent arefully incorporated herein.

Prior to the application of slurry at outlet 38(a), the edges of mat 22,along with the secured film 32, can be folded upwardly via crimpingrollers to create a containment envelope at the edges of the board. Thisprevents, or greatly lessens, the amount of slurry that leaks from thesides of the board during subsequent processing. A suitable edge foldingmechanism is disclosed in commonly owned U.S. Pat. No. 6,524,679 toHauber. The contents of this patent are fully incorporated herein.

In the production of EGRG boards, after slurry is supplied at outlet38(a), mat 22 passes through a pair of opposing roller coaters 40.Roller coaters 40 function in assuring that slurry 26 penetrates glassmat 22 and coats the individual fibers. During this penetration, film 32functions as a containment envelope and prevents slurry from leakingthrough the bottom of mat 22 and contaminating the underlying formingtable. Roller coaters 40 also ensure that a dense slurry layer 30 isformed between lower mat 22 and film 32(note FIG. 5a ). The slurrydensity achieved by roller coaters 40 is greatly improved via thecontainment functions of the film 32 and folded edges. The increaseddensity, in turn, allows for better slurry penetration and the neartotal embedment of mat fibers.

However, the method disclosed herein can also be utilized in theproduction of GRG boards, such as the boards disclosed in U.S. Pat. No.4,265,979. In this embodiment, gypsum core 26 is applied over top of mat22 but does not fully penetrate mat 22. This lack of penetration resultsin voids being present along the boundary of film 32 and underlying mat22. Some of these voids are subsequently filled with slurry from core26. However, because mat 22 is not fully embedded, some voids arepresent in the finished board. This results in a board with lessadherence and a looser bond between film 32 and mat 22.

After the application of slurry at outlet 38(a), and as illustrated inFIG. 1, a forming belt 42 transports the partially formed board to asecond slurry outlet 38(b) where a second layer of gypsum slurry 26 isapplied directly over the first layer. As noted above, slurry suppliedby outlet 38(b) is preferably less dense than the slurry provided atoutlet 38(a). Vibrators 60 underlying the forming table can be employedto remove any air voids and to ensure mat 22 is completely embeddedwithin slurry 26. This second layer forms the major part of the slurrycore 26. During the application of slurry, in multiple layers orotherwise, the un-dissolved film laminate 32 continues to act as acontainment envelope to prevent slurry from leaking onto the underlyingforming equipment.

With continuing reference to FIG. 1, an upper glass fiber mat 24 isapplied to the exposed slurry to form a composite panel. Upper glass mat24 is supplied from an additional glass mat roll 28(a) and associatedguide rollers. In the disclosed embodiment, mats 22 and 24 have anidentical construction. However, depending upon the desired application,it is within the scope of the present invention to use differingconstructions for mats 22 and 24. It is also within the scope of thepresent invention to employ a PHOV film 32 overtop of mat 24. Such afilm would be applied prior to mat 24 being delivered to associatedroller coaters and would otherwise be adhered in a fashion similar tothe application of film 32 to mat 22 as described above. However, in thepreferred embodiment depicted in FIGS. 1-5, film 32 is limited to lowermat 22.

A layer of slurry is thereafter applied to the face of mat 24 via slurryoutlet 38(c). Slurry from outlet 38(c) can be applied at a separateforming table if desired. Again, slurry from outlet 38(c) can have ahigher density than the slurry from outlet 38(b). As described above inconnection with EGRG board production, roll coaters can be used to forcethe slurry through mat 24 to create a thin surface layer of slurry 30.

Upper mat 24 (with or without an adhered film layer 32) is thendelivered via transfer rollers over top of slurry core 26 and the lowermat 22 to form a composite panel. In the event edges of mat 22 arefolded, the lateral edges of mat 24 are adhered to the folded edges ofmat 22, with the tackiness of film 32 functioning as an adhesive.Alternatively, an adhesive can be applied between the lateral edges ofmat 24 and the folded edges of mat 22.

The composite panel is then delivered to a forming plate 44. Formingplate 44 further compacts the applied slurry and constrains the panel toa desired thickness. During this process, additional slurry is forcedthrough and over underlying mat 22. Excess slurry is prevented fromcontacting the underlying forming belt 42, associated drives, bearings,and other surfaces by the way of the un-dissolved film 32. Film 32continues to perform this containment function as the board travelsalong the various stages of production line 10.

Next, as illustrated in FIG. 2, forming belt 42 routes the panel to aroller section 48 and an associated cutting station. At the cuttingstation, knifes 50 cuts the panel into a number of discrete buildingboards of a desired length. The building boards can be cut into anylength that is desired for various purposes. The individual boards arethen passed along accelerator belts to a flipping table 54. At flippingtable 54, the individual building boards are turned over. As a result,film 32 underlying lower (or first) glass mat 22 is exposed (compareFIGS. 5a and 5b ). Likewise, upper (or second) glass mat 24 and coveringgypsum layer 30 are placed in facing relation with the forming belt 42following flipping table 54.

As noted in FIG. 3, a transfer table 58 delivers the individual boardsto the infeed section 62 of the first dryer zone 64(a). It is importantto maintain the integrity of film 32 prior to the boards being deliveredto the infeed section 62 of dryers 64. Namely, film 32 should remainnon-porous as the boards are being transferred and flipped. Maintainingfilm integrity ensures that wet slurry does not come into contact withthe forming equipment as noted above.

Thereafter, as is conventional in the manufacture of gypsum buildingproducts, a series of dryers are utilized to heat the gypsum within thepanels and vaporize any non-crystalline water. In the depictedembodiment, there are four dryer zones 64(a), 64(b), 64(c) and 64(d).However, the number of dryer zones employed is not critical to thepresent invention. Dryers 64 are designed to heat the building boards toa degree sufficient to cure the gypsum. This is typically achieved at atemperature of approximately 212° F. The presence of entrained waterwithin the gypsum core will generally prevent the temperature of thegypsum core from raising above 212° F. Dryers 64 of the depictedembodiment utilize a conventional construction and run at temperaturelevels that range anywhere between approximately 650° F. to 180° F.,which is typical for gypsum drying operations.

As a result of this heating process, water is vaporized and deliveredupwardly through film 32. PVOH films are advantageous because theybecome porous when heated, thereby allowing water vapor to escape andavoiding blistering. The escaping water vapor, and the exothermic natureof gypsum rehydration, also furthers the dissolution of the PVOH film.Thus, the dissolution characteristics of PHOV films are dependent upontime and exposure to heat and water vapor. In the context of a boarddryer, PVOH films start to become permeable at approximately 60° F. andachieve total permeability at approximately 212° F. Other films can bechosen to achieve total film dissolution at between 110° F. and 120° F.Films that have no dissolution state, or that are less porous, are notdesirable because they do not adequately allow for the passage ofvaporized water and therefore result in blistering.

The passage of water vapor through film 32 serves to liquefy the film32. This, in turn, results in the liquefied PVOH film melting downwardlyover mat 22 (note FIG. 5c ). Embedding mat 22 within core 26 serves tocoat most, but not all, of the exposed fibers of mat 22. Any fibers leftexposed after embedment are subsequently completely coated by dissolvedfilm 32. This prevents the disengagement of loose fibers.

The dissolved PVOH film also sinks into the face of the board and ispartially absorbed by gypsum core 26. After film 32 has been absorbed,the PVOH film 32 may chemically bond with other polymers additiveswithin core 26. Such bonding may be accomplished during curing. In stillyet other embodiments, film 32 includes polymer additives that bond toadditives within gypsum core 26. These additives can be selected toenhance any of a variety of physical properties and may impart, forexample, increased board strength, water resistance, mold protection,and or ultraviolet protection.

By the end of the fourth dryer zone 64(d), film 32 is completelydissolved. Depending on the composition of film 32, it may betranslucent, partially translucent, or opaque upon dissolution. Acoloring can also be imparted to the board by way of film 32. Theapplication of the liquefied PVOH film to the panel provides a smootherfinish and results in a building board with superior water resistance.In the preferred embodiment, the resulting board has a moistureresistance that meets the American Society of Testing and Materialsstandard ASTM-C 1177. The resulting board has a smoother texture byvirtue of film 32 and therefore exhibits improved bonding to paints andjoint compounds.

The method described above utilizes a dissolvable film 32 in theconstruction of GRG or EGRG building boards. However, the method canalso be applied to other building board constructions. Film 32 hasprimarily been disclosed as a containment envelope with the filmintegrity being maintained at all points prior to the boards beingdried. Namely, film 32 can be adhered to mat 22 via an adhesive, withfilm 32 being dissolved in the presence of water vapor and at atemperature at or above 212° F. However, the present method also allowsfor the controlled dissolution of film 32 at any point in the process.For instance, film can be used as a slip sheet between the board andunderlying forming table. Film 32 can also be made from materials thatdissolve as a result of the exothermic reaction and/or watercondensation associated with setting gypsum. More specifically, film 32can be selected to realize complete film dissolution at any point duringthe process. This dissolution point can be selected based upon thespecific objectives of the manufacturing process. For example, incertain circumstances the gypsum may be cured prior to passage throughone or more driers. This may be carried out, for instance, via knownultraviolet (UV) curing processes. In this instance, it would bedesirable to affect dissolution of film 32 at an earlier point duringthe board manufacturing process.

The present disclosure includes that contained in the appended claims,as well as that of the foregoing description. Although this inventionhas been described in its preferred form with a certain degree ofparticularity, it is understood that the present disclosure of thepreferred form has been made only by way of example and that numerouschanges in the details of construction and the combination andarrangement of parts may be resorted to without departing from thespirit and scope of the invention.

What is claimed is:
 1. A composite building panel comprising: first andsecond glass fiber mats, each mat having an interior and an exteriorsurface; a dissolvable film adhered to the exterior surface of the firstmat, the film being completely dissolvable in the presence of heat andwater; a gypsum slurry layer with entrained water deposited between theinterior surfaces of the first and second mats, the deposited slurrypassing through the exterior surface of the first mat but beingcontained by the adhered film, the entrained water being vaporized whenheated; wherein the film allows for the passage of the vaporized water,and wherein the film subsequently dissolves in the presence of heat andvaporized water with the dissolved film adhering to the fibers of thefirst mat to enhance the physical properties of the composite panel. 2.The composite panel as described in claim 1 wherein the fiber mats areeach formed from a plurality of randomly aligned glass fibers.
 3. Thecomposite panel as described in claim 1 wherein the dissolvable film isformed from a Polyvinyl Alcohol (PVOH).
 4. The composite panel asdescribed in claim 1 wherein the dissolvable film is formed from anEthylene Vinyl Alcohol (EVA).
 5. The composite panel as described inclaim 1 wherein the dissolvable film is formed from a water soluble,synthetic polymer.
 6. The composite panel as described in claim 1wherein the dissolvable film is a polyethylene-based composite film. 7.The composite panel as described in claim 1 wherein the dissolvable filmis between approximately 0.5 and 2.5 mils thick.
 8. The composite panelas described in claim 1 wherein the dissolvable film is secured via aheat activated adhesive.
 9. The composite panel as described in claim 1wherein the film Previously becomes liquefied via the passage of thevaporized water.
 10. The composite panel as described in claim 1 whereinthe dissolved film is partially absorbed by the gypsum slurry.
 11. Acomposite building panel comprising: first and second fiber mats, eachmat having an interior and an exterior surface; a dissolvable filmadhered to the exterior surface of at least one of the fiber mats, thefilm being completely dissolvable in the presence of heat or water; aslurry layer with entrained water deposited between the interiorsurfaces of the first and second mats, the deposited slurry passingthrough the exterior surface of the mats but being contained by thedissolvable film; wherein vaporized water passes through and completelydissolves the film, and wherein the dissolved film adheres to the fibersof the mat to enhance the physical properties of the composite panel.12. The composite panel as described in claim 11 wherein the dissolvablefilm is formed from a Polyvinyl Alcohol (PVOH).
 13. The composite panelas described in claim 11 wherein the dissolvable film is formed from anEthylene Vinyl Alcohol (EVA).
 14. The composite panel as described inclaim 11 wherein the dissolved film is partially absorbed by the gypsumslurry.